Hydraulic Cylinder

Unit
(HCU)

PrimeServ Academy Copenhagen

Learning objectives

Upon completion of this module you …

 will be able to recognize the various parts in the HCU
system.
 will be able to explain the HCU system.

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Agenda
Hydraulic Cylinder Unit (HCU)

1 High pressure pipes

2 Distribution block
3 Components:
 Accumulators
 Lubricator
4 Lubrication

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Hydraulic Cylinder Unit (HCU)
High pressure pipes – 200 or 300 bars system

Double wall pipe,

200 bar system

Single pipe in casing

300 bar system

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Hydraulic Cylinder Unit (HCU)
High pressure pipes – 200 or 300 bars system

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Hydraulic Cylinder Unit (HCU)
High pressure pipes – 200 bars pipe

Outer pipe
Sealing rings Inner pipe Sealing rings

Screws

Slide bearings
Flange

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Hydraulic Cylinder Unit (HCU)
High pressure pipes – Leak detection 200 bars system

1. CLOSE the valve 430 at the last, but one Hydraulic

Cylinder Unit (HCU).
2. OPEN the valve 431 at the last HCU to decrease
the pressure in the space between the inner and
outer pipe.
3. CLOSE the valve 431 at the last HCU again.
4. Check the pressure increase in the space between
at position 435, at the last HCU.
5. If the pressure increases to system pressure level,
the leakage has been found.
6. When the leakage has been eliminated, bring all the
valves to their normal position.

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Agenda
Hydraulic Cylinder Unit (HCU)

1 High pressure pipes

2 Distribution block
3 Components:
 Accumulators
 Lubricator
4 Lubrication

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Hydraulic Cylinder Unit (HCU)
Distribution block

Front side Back side

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Hydraulic Cylinder Unit (HCU)
Distribution block

Fuel oil Exhaust valve

pressure booster actuator

Overflow pipe
(de - air rating)
Accumulator

Distribution
block
ME lubricator
FIVA valve

Ball valve

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Hydraulic Cylinder Unit (HCU)
Distribution block – 200 bars system diagram

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Hydraulic Cylinder Unit (HCU)
Distribution block – 300 bars system diagram

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Hydraulic Cylinder Unit (HCU)
Distribution block – 200 bars system valves

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Hydraulic Cylinder Unit (HCU)
Distribution block – 300 bars system valves

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Hydraulic Cylinder Unit (HCU)
Distribution block – Preparation for maintenance

CAUTION!
HCU OVERHAULING
0. CHECK GAUGE WORKS!
1. CLOSE VALVE NO. 420, 531
2. OPEN VALVE NO. 421, 405, 406
3.CHECK PRESSURE AT MEASURING POINT 455.
WARNING – NEVER ’OPEN’ VALVE 420 WHEN
SYSTEM PRESSURE IS ’ON’

Valve No.

CAUTION!
LUBRICATION OVERHAULING
0. CHECK GAUGE WORKS!
1. CLOSE VALVE NO. 560
2. CHECK PRESSURE AT MEASURING
POINT 565
3. IF PRESSURE IS PRESENT, PRESS THE
’PRE-LUB’ BUTTON AT THE HMI PANEL.

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Agenda
Hydraulic Cylinder Unit (HCU)

1. High pressure pipes

2. Distribution block
3. Components:
– Accumulators
– Lubricator
4. Lubrication

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Hydraulic Cylinder Unit (HCU)
Accumulators

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Hydraulic Cylinder Unit (HCU)
Accumulators – Nitrogen check, SL2019 - 673

The accumulator charge pressure For the 300 bar HPS accumulator
should be checked within the first charging pressures are:
week of service. Next check should
be made minimum every month.
A minor leakage from the
accumulators is unavoidable and
service experience shows that a
pressure drop in the range of
2 - 5 bar / month is to be expected.
The charge pressure is dependent
on working servo oil pressure as
well as the accumulator
temperature.

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Agenda
Hydraulic Cylinder Unit (HCU)

1. High pressure pipes

2. Distribution block
3. Components:
– Accumulators
– Lubricator
4. Lubrication

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Hydraulic Cylinder Unit (HCU)
Lubricator - Diagram

High BN Low BN

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Hydraulic Cylinder Unit (HCU)
Lubricator - Components

Distribution block

Level sensor
ME lubricator

Pilot valve Piston movement feedback

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Hydraulic Cylinder Unit (HCU)
Lubricator – Injection nozzles

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Hydraulic Cylinder Unit (HCU)
Lubricator – Liner Groves

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Hydraulic Cylinder Unit (HCU)
Lubricator – ME lubricator design

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Hydraulic Cylinder Unit (HCU)
Lubricator – Cylinder lubrication screen

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Hydraulic Cylinder Unit (HCU)
Lubricator – Wear rate / Oil dosage

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Hydraulic Cylinder Unit (HCU)
Lubricator - Backup

In case of CCU failure where the CCU cannot be

changed immediately, the cylinder lubrication can be
achieved by a temporary cable from one of the ECU
units, plug 52, to the solenoid valve on the lubricator on
the unit in question.
The lubrication will be with random timing:

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Hydraulic Cylinder Unit (HCU)
Lubricator - Backup

Cylinder lubrication
backup cable

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Hydraulic Cylinder Unit (HCU)
Lubricator - Backup

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Hydraulic Cylinder Unit (HCU)
Lubricator – Alpha lubricator Mk. II

Level sensor

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Hydraulic Cylinder Unit (HCU)
Lubricator – Alpha lubricator Mk. II

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Hydraulic Cylinder Unit (HCU)
Lubricator – Alpha lubricator Mk. II; Working principle

The possibility for up to two injections per revolution

with different timing / amount
Every injection timing is decided according to Top Dead
Center (TDC) for the actual cylinder.

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Agenda
Hydraulic Cylinder Unit (HCU)

1. High pressure pipes

2. Distribution block
3. Components:
 Accumulators
 Lubricator
4. Lubrication

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Hydraulic Cylinder Unit (HCU)
Lubrication – How to…

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Disclaimer

All data provided in this document is non-binding.

This data serves informational purposes only and is especially not guaranteed in any way.
Depending on the subsequent specific individual projects, the relevant data may be subject to changes and
will be assessed and determined individually for each project. This will depend on the particular characteristics
of each individual project, especially specific site and operational conditions.

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PrimeServ Academy Copenhagen